Method for Manufacturing a Flame Arrestor

ABSTRACT

A method of custom manufacturing a flame arrestor assembly configured to extinguish a flame propagating therethrough. The method includes creating a customized flame cell using an additive manufacturing technique, which generally includes forming a body and forming one or more channels in the body. The one or more channels define a flow path configured to transfer heat from a flame front propagating through the flow path to the body. The method also includes providing a housing, and securely arranging the flame cell within the housing.

FIELD OF THE DISCLOSURE

The present disclosure generally relates to flame arrestors, and, moreparticularly, to a method of manufacturing a flame arrestor.

BACKGROUND

Flame arrestors can be employed in applications, e.g., chemical,refining, petrochemical, upstream oil and gas, landfill, biogasapplications, and the like, involving flammable vapors so as to preventthe flammable vapors from being ignited by potential ignition sources(e.g., flares, flames, exothermic chemical reactions, failed compressorbearings, etc.), which could lead to a fire, a deflagration, and/or adetonation. Flame arrestors, which may, for example, be installed in apipeline between a fuel source (e.g., one or more storage tanks) and anignition source (e.g., a flare, a flame), include flow paths thatfacilitate fluid flow therethrough, but, at the same time, remove heatfrom a flame front (which may also be referred to as the flame) as itattempts to flow through these flow paths. Flame arrestors thus preventthe flame front from reaching the fuel source, thereby preventingignition of the fuel source, and, in turn, injuries, environmentalissues, and/or damage to equipment and facilities that may result fromsuch an ignition.

With conventional manufacturing processes, flame arrestors, such as theflame arrestor 100 of an element assembly shown in FIGS. 1A and 1B,include one or more flame cells 104 that are installed (e.g., welded,captured by welded rings or crossbars) in the housing 108 and feature aplurality of narrow, linear flame paths 112 that serve to remove heatfrom a flame front that attempts to flow therethrough, as describedabove. As best illustrated in FIG. 1B, each of the flame cells 104employs multiple layers 116 of crimped metal ribbons that are woundaround a core 120 and define or create a plurality oftriangularly-shaped openings 124, which in turn define or create thelinear flame paths 112. In some cases, e.g., when the flame arrestor 100includes multiple flame cells 104, as is the case in FIGS. 1A and 1B(which depicts four flame cells 104), a sheet of expanded metal or ascreen 128 must be installed within the housing 104 between each pair ofadjacent flame cells 104 so as to create a level of turbulence thatensures adequate heat removal as the flame front travels through theflame arrestor 100.

SUMMARY

In accordance with a first exemplary aspect of the present invention, aflame cell is provided. The flame cell includes a body and one or morechannels formed in the body. The one or more channels define anon-linear flow path, and the body is configured to remove heat from aflame front propagating through the non-linear flow path.

In accordance with a second exemplary aspect of the present invention, aflame arrestor is provided. The flame arrestor includes a housing, and aflame cell arranged in the housing. The flame cell includes a means forinducing turbulence in a flame propagating through the flame arrestor.

In accordance with a third exemplary aspect of the present invention, amethod of custom manufacturing a flame arrestor assembly is provided.The method includes creating a customized flame cell using an additivemanufacturing technique, which generally includes forming a body andforming one or more channels in the body. The one or more channelsdefine a flow path configured to transfer heat from a flame frontpropagating through the flow path to the body. The method also includesproviding a housing, and securely arranging the flame cell within thehousing.

In further accordance with any one or more of the foregoing first,second, and third exemplary aspects, a flame cell, a flame arrestor, andor a method of manufacturing a flame arrestor assembly may include anyone or more of the following further preferred forms.

In one preferred form, one or more of the channels are curved.

In another preferred form, the non-linear flow path has a helical shape.

In another preferred form, at least one of the channels includes acomponent oriented substantially perpendicular to a longitudinal axis ofthe flame cell.

In another preferred form, each of the channels has a circularcross-sectional shape.

In another preferred form, each of the channels has an irregularcross-sectional shape.

In another preferred form, the means for inducing turbulence comprises aplurality of channels that define a non-linear flow path.

In another preferred form, the flame cell includes a body made of ametallic material, the channels being formed in the body.

In another preferred form, a second flame cell is arranged in thehousing, the second flame cell including a second means for inducingturbulence in the flame propagating through the flame arrestor.

In another preferred form, the flame cell and the second flame cell arenot separated by expanded metal.

In another preferred form, the second means for inducing turbulenceincludes a second plurality of channels that define a second non-linearflow path different from the non-linear flow path.

In another preferred form, each of the channels has a circular,rectangular, or irregular cross-sectional shape.

In another preferred form, the means for inducing turbulence is not asheet of expanded metal disposed in the flame cell.

In another preferred form, the act of creating the customized flame cellincludes forming a void in the body, and the method further includesarranging a sensor within the void.

In another preferred form, the act of providing the housing includescreating the housing using the additive manufacturing technique.

In another preferred form, the method further includes creating anadditional customized flame cell using the additive manufacturingtechnique, and securely arranging the additional flame cell within thehousing.

In another preferred form, the additive manufacturing technique includes3D printing.

In another preferred form, the act of forming the one or more channelsincludes forming one or more curved channels in the body such that theflow path is at least partially non-linear.

BRIEF DESCRIPTION OF THE DRAWINGS

The features of this invention which are believed to be novel are setforth with particularity in the appended claims. The invention may bebest understood by reference to the following description taken inconjunction with the accompanying drawings, in which like referencenumerals identify like elements in the several FIGS., in which:

FIG. 1A is a cross-sectional view of a conventional flame arrestorassembly;

FIG. 1B is a perspective view of a portion of the conventional flamearrestor assembly of FIG. 1A;

FIG. 2 is a schematic diagram of one example of a process or methodaccording to the teachings of the present disclosure for manufacturing aflame arrestor;

FIG. 3A is an end view of one example of a flame cell manufacturedaccording to the process of FIG. 2 and including channels having across-like cross-sectional shape;

FIG. 3B is an end view of one example of a flame cell manufacturedaccording to the process of FIG. 2 and including channels having ahexagonal cross-sectional shape;

FIG. 3C is an end view of one example of a flame cell manufacturedaccording to the process of FIG. 2 and including channels having anoctagonal cross-sectional shape;

FIG. 3D is an end view of one example of a flame cell manufacturedaccording to the process of FIG. 2 and including channels having acircular cross-sectional shape;

FIG. 3E is an end view of another example of a flame cell manufacturedaccording to the process of FIG. 2 and including channels having acircular cross-sectional shape;

FIG. 3F is an end view of one example of a flame cell manufacturedaccording to the process of FIG. 2 and including channels having anirregularly-shaped cross-section;

FIG. 3G is an end view of another example of a flame cell manufacturedaccording to the process of FIG. 2 and including channels having anirregularly-shaped cross-section;

FIG. 3H is an end view of one example of a flame cell manufacturedaccording to the process of FIG. 2 and including channels having atriangular cross-sectional shape and arranged in an alternating pattern;

FIG. 4A is a perspective view of a flame cell manufactured according tothe process of FIG. 2 and defining a first example of a complex flowpath;

FIG. 4B is a perspective view of a flame cell manufactured according tothe process of FIG. 2 and defining a second example of a complex flowpath;

FIG. 4C is a perspective view of a flame cell manufactured according tothe process of FIG. 2 and defining a third example of a complex flowpath;

FIG. 4D is a perspective view of a flame cell manufactured according tothe process of FIG. 2 and defining a fourth example of a complex flowpath; and

FIG. 5 is a cross-sectional view of a flame cell manufactured accordingto the process of FIG. 2 and including a plurality of curved channels.

DETAILED DESCRIPTION

The present disclosure is generally directed to a method ofmanufacturing a flame arrestor that removes heat from a flame front in amore efficient manner and requires less maintenance than conventionallymanufactured flame arrestors such as the flame arrestor 100. The methoddescribed herein utilizes cutting edge manufacturing techniques, likeadditive manufacturing, to facilitate custom manufacturing of the flamearrestor, as well as various components of the flame arrestor (e.g., oneor more flame cells), such that a number of different unique and complexflow paths, e.g., non-linear flow paths, can be developed andincorporated into the resulting flame arrestor in place of the standard,linear flow paths utilized in conventional flame arrestors, dependingupon the given application. Unique and complex flow paths promote orinduce turbulent flow and encourage nearly continuous (or at leastincreased) heat transfer from a flame front to the flame arrestor, suchthat flame arrestors produced according to the method of manufacturingdescribed herein represent an improvement over known flame arrestors.

Beneficially, these unique and complex flow paths also obviate the needfor screens or expanded metal, which are sometimes needed inconventional flame arrestors to promote turbulent flow but undesirablyresult in a large pressure drop across the flame arrestor and may, insome cases, plug the flame cells. In other words, the method describedherein can yield a flame arrestor that induces a greater level ofturbulent flow than conventional flame arrestors, without producing thenegative effects (i.e., a large pressure drop and increased maintenancedue to plugging) caused by turbulence inducing screens or expandedmetal. In some cases, the method described herein may also reduce thenumber of flame cells that need to be utilized in a given flamearrestor, such that less material is required, thereby reducing theweight and/or manufacturing cost of the flame arrestor. This also hasthe potential benefit of facilitating a shorter flame arrestor (as lessflame cells are used), which will in turn reduce pressure drops withinthe flame arrestor.

FIG. 2 is a diagram of an example of a method or process 200 accordingto the teachings of the present disclosure. The method or process 200schematically depicted in FIG. 2 is a method or process of custommanufacturing a flame arrestor (also referred to herein as a flamearrestor assembly). Like the conventional flame arrestors describedabove (e.g., the flame arrestor 100), flame arrestors manufacturedaccording to the method or process 200 are configured to remove heatfrom a flame front, thereby preventing (e.g., extinguishing) a flamefrom propagating therethrough, but, as described above, does so in amanner that is more efficient and requires less maintenance.

More specifically, the method 200 includes the act 204 of creating acustomized flame cell using an additive manufacturing technique. Theadditive manufacturing technique may be any additive manufacturingtechnique or process that builds three-dimensional objects by addingsuccessive layers of material on a material. The additive manufacturingtechnique may be performed by any suitable machine or combination ofmachines. The additive manufacturing technique may typically involve oruse a computer, three-dimensional modeling software (e.g., ComputerAided Design, or CAD, software), machine equipment, and layeringmaterial. Once a CAD model is produced, the machine equipment may readin data from the CAD file and layer or add successive layers of liquid,powder, sheet material (for example) in a layer-upon-layer fashion tofabricate a three-dimensional object. The additive manufacturingtechnique may include any of several techniques or processes, such as,for example, a stereolithography (“SLA”) process, a fused depositionmodeling (“FDM”) process, multi-jet modeling (“MJM”) process, aselective laser sintering (“SLS”) process, an electronic beam additivemanufacturing process, and an arc welding additive manufacturingprocess. In some embodiments, the additive manufacturing process mayinclude a directed energy laser deposition process. Such a directedenergy laser deposition process may be performed by a multi-axiscomputer-numerically-controlled (“CNC”) lathe with directed energy laserdeposition capabilities.

The act 204 of creating the customized flame cell thus generallyincludes forming a body and forming one or more channels in the body.The body can be made of one or more suitable materials, such as, forexample, stainless steel, aluminum, various alloys (e.g., high nickelalloys), and by virtue of being customizable, can be any number ofdifferent shapes and/or sizes. The one or more channels generally definea flow path that is configured to transfer heat from a flame frontpropagating through the flow path to the body.

The one or more channels, which generally extend between opposing endsof the flame cell, can, by virtue of being customizable, have any numberof different sizes and/or shapes in cross-section, and/or be arranged inany number of different patterns or arrays. Generally speaking, each ofthe one or more channels will have a cross-sectional shape that is notlimited to being triangular. As examples, FIG. 3A illustrates channels300 having a cross-like cross sectional shape, FIG. 3B illustrateschannels 300 having an hexagonal cross-sectional shape, FIG. 3Cillustrates channels 300 having an octagonal cross-sectional shape,FIGS. 3D and 3E each illustrate channels 300 having a circularcross-sectional shape, FIGS. 3F and 3G each illustrate channels 300having irregularly-shaped cross-sections. Alternatively, each of thechannels 300 may have a triangular cross-sectional shape, with thosechannels 300 arranged in the alternating pattern illustrated in FIG. 3H.Other cross-sectional shapes are possible as well. It will also beappreciated that one or more of the channels may have a different shapeand/or size than one or more other channels, as illustrated in, forexample, FIG. 3D, wherein all of the channels 300 have a circular shapein cross-section, but some of the channels 300 are larger in diameterthan the other channels 300.

As discussed above, the usage of additive manufacturing techniques tocustom manufacture the flame cell allows the one or more channels to beformed so as to define a unique and complex, e.g., a non-linear orcurved flow path, rather than the standard, linear flow paths utilizedin conventional flame arrestors. This is generally accomplished by orvia (i) the unique and complex shape of the one or more channels, (ii)rotating the one or more channels about an axis that extends along or isparallel to a centerline of the flame cell, and/or (iii) changing theposition of the one or more channels relative to the centerline as thechannels extend through the flame cell, such that the one or morechannels move away from and/or toward the centerline as the channelsextend through the flame cell.

Various portions of the channels may, in turn, be oriented at differentangles relative to the axis. As an example, a first portion of one ofthe channels may be oriented at a first angle relative to the axis,while a second portion of that channel may be oriented at a second anglerelative to the axis, the second angle being greater than or less thanthe first angle. In some cases, one or more portions or components ofthe channels may be oriented substantially perpendicular or exactlyperpendicular relative to the axis of the flame cell. Moreover, whilenot illustrated herein, different channels may be rotated relative toone another and/or converge toward or diverge away from one another.

FIG. 4A illustrates one example of a flame cell 400 having a unique orcomplex flow path 404 defined or formed by one or more channels 408 (inthis case, one channel 408) having the cross-like cross-sectional shapeillustrated in FIG. 3A. As illustrated, the channel 408 extends betweena first end 412 of the flame cell 400 and a second end 416 of the flamecell 400 opposite the first end 408.

FIG. 4B illustrates one example of a flame cell 420 having a non-linearor curved flow path 424 formed by rotating one or more channels 428 (inthis case, one channel 428) about a central axis 432 of the flame cell420. The channel 428 depicted in FIG. 4B has a circular shape incross-section. As illustrated, the channel 428 is centered on or aboutthe axis 432 at opposing ends 436 of the flame cell 420, but is rotated(e.g., spiraled, wound) about the axis 432 between the ends 436, suchthat the non-linear flow path 400 takes on a helical form.

FIG. 4C illustrates another example of a flame cell 440 having anon-linear or curved flow path 444 formed by rotating one or morechannels 448 (in this case, one channel 448) about a central axis 452 ofthe flame cell 440. The channel 448 depicted in FIG. 4C has a cross-likeshape in cross-section. As illustrated, the channel 448 is centered onor about the axis 452 at opposing ends 456 of the flame cell 440, but isrotated about the axis 452 between the ends 456.

FIG. 4D illustrates one example of a flame cell 480 having a non-linearor curved flow path 484 formed by changing the position of one or morechannels 488 (in this case, one channel 488) about a central axis 492 ofthe flame cell 480. The channel 488 depicted in FIG. 4D has asubstantially rectangular shape in cross-section. As illustrated, thechannel 488 is centered on or about the center axis 492 at opposing ends496 of the flame cell 480, but has two portions 498A that increasinglyextend away from the center axis 492 and two portions 498B thatincreasingly extend toward the center axis 492, such that the flow path484 zigzags through the flame cell 480.

It will be appreciated that the flame cell can include other unique andcomplex flow paths depending on the given application. In some cases,the unique and complex flow path can partially include a linear orstraight portion, with the remaining portion being curved or non-linear.

In some cases, the act 204 of creating the customized flame celloptionally includes forming a void in the body of the flame cell, andarranging a sensor within the void. The sensor can, for example, be atemperature, photo, infrared, pressure, or other type of sensor. Thesensor can, in turn, be communicatively connected (either via a wiredconnection or a wireless connection) to a controller, thereby allowingthe controller and/or a user to remotely monitor the flame cell withouthaving to shut down the system employing the flame cell. This allows thecontroller and/or the user to, for example, remotely monitor or detectthe temperature or pressure within the flame cell (e.g., the temperatureof the body, the temperature of the flame front), as well as otherparameters and data, as desired.

The method or process 200 also includes the act 208 of providing ahousing for the flame cell. The housing generally includes an inletarranged to be coupled to an upstream component of the pipeline in whichthe flame arrestor is employed, as well as an outlet arranged to becoupled to a downstream component of the pipeline. The housing alsoincludes a chamber or cavity sized to receive the flame cell, as well asadditional components for securely retaining the flame cell within thehousing.

In some cases, the act 208 of providing the housing for the flame cellmay involve manufacturing the housing using conventional manufacturingtechniques, either before, after, or at the same time as the act 204 isperformed. In other cases, however, the act 208 of providing the housingfor the flame cell may involve creating the housing using one of theadditive manufacturing techniques described above. The housing may becreated using a different additive manufacturing technique as the flamecell or using the same additive manufacturing technique as the flamecell. In either situation, the housing may be created before, after, orat the same time as the flame cell is created.

The method or process 200 further includes the act 212 of securelyarranging the created flame cell within the provided housing, therebyforming the flame arrestor. In some cases, e.g., when the housing ismanufactured using conventional techniques, the created flame cell maybe secured within the housing using threaded bolts or any other knownsuitable means. In other cases, e.g., when the housing is manufacturedusing the same additive manufacturing technique used to manufacture theflame cell, the flame cell can be secured within the housing by printingthe flame cell onto the housing (using additive manufacturing), therebyforming a unitary, one-piece flame arrestor.

It will be appreciated that the acts 204, 208, and/or 212 can beperformed any number of different times. In some cases, the act 204 canbe performed multiple times so as to create multiple (e.g., two, three,four, and so on) flame cells for use in a single housing. Beneficially,because the flame cells will promote greater levels of turbulent flowthan conventional flame arrestors, the flame cells can be arrangedwithin the housing, adjacent one another, without having to disposescreens or expanded metal therebetween, as is the case in someconventional flame arrestors. In other cases, the act 204 can beperformed multiple (e.g., two, three, four, and so on) times, with theacts 208 and 212 also performed multiple times, so as to create multipleflame arrestors each having a single flame cell.

FIG. 5 illustrates another example of a flame cell 500 custommanufactured using the method or process 200. The flame cell 500 has asubstantially cylindrical body 504 and a plurality of channels 508formed or defined in the body 504. Each of the channels 508 has acircular shape in cross-sectional and extends between a first end 512 ofthe flame cell 500 and a second end 516 of the flame cell 500 oppositethe first end 512. As illustrated, each of the channels 508 is curvedbetween the first and second ends 512, 516, such that the channels 508define a curved, or non-linear, flow path. As discussed above, thiscurved, or non-linear, flow path advantageously promotes or inducesturbulent flow so as to ensure adequate heat transfer from the flamefront to the flame cell 500 as fluid flows through the flame cell 500.The flame cell 500 also includes a void 520 that is formed or defined inthe body 504 during manufacturing and is sized to receive a sensor 524(e.g., a temperature, photo, infrared, pressure, or other type ofsensor). While not depicted herein, the sensor 524 can becommunicatively connected (either via a wired connection or a wirelessconnection) to a controller, thereby allowing the controller and/or auser to remotely monitor the flame cell 500 without having to shut downthe system employing the flame cell 500.

Preferred embodiments of this invention are described herein, includingthe best mode or modes known to the inventors for carrying out theinvention. Although numerous examples are shown and described herein,those of skill in the art will readily understand that details of thevarious embodiments need not be mutually exclusive. Instead, those ofskill in the art upon reading the teachings herein should be able tocombine one or more features of one embodiment with one or more featuresof the remaining embodiments. Further, it also should be understood thatthe illustrated embodiments are exemplary only, and should not be takenas limiting the scope of the invention. All methods described herein canbe performed in any suitable order unless otherwise indicated herein orotherwise clearly contradicted by context. The use of any and allexamples, or exemplary language (e.g., “such as”) provided herein, isintended merely to better illuminate the aspects of the exemplaryembodiment or embodiments of the invention, and do not pose a limitationon the scope of the invention. No language in the specification shouldbe construed as indicating any non-claimed element as essential to thepractice of the invention.

1. A flame cell, comprising: a body; and one or more channels formed inthe body, the one or more channels defining a non-linear flow path,wherein the body is configured to remove heat from a flame frontpropagating through the non-linear flow path.
 2. The flame cell of claim1, wherein one or more of the channels are curved.
 3. The flame cell ofclaim 1, wherein the non-linear flow path has a helical shape.
 4. Theflame cell of claim 1, wherein at least one of the channels comprises acomponent oriented substantially perpendicular to a longitudinal axis ofthe flame cell.
 5. The flame cell of claim 1, wherein each of thechannels has a circular cross-sectional shape.
 6. The flame cell ofclaim 1, wherein each of the channels has an irregular cross-sectionalshape.
 7. A flame arrestor, comprising: a housing; and a flame cellarranged in the housing, the flame cell comprising a means for inducingturbulence in a flame propagating through the flame arrestor.
 8. Theflame arrestor of claim 7, wherein the means for inducing turbulencecomprises a plurality of channels that define a non-linear flow path. 9.The flame arrestor of claim 8, wherein the flame cell comprises a bodymade of a metallic material, the channels being formed in the body. 10.The flame arrestor of claim 7, further comprising a second flame cellarranged in the housing, the second flame cell comprising a second meansfor inducing turbulence in the flame propagating through the flamearrestor.
 11. The flame arrestor of claim 10, wherein the flame cell andthe second flame cell are not separated by expanded metal.
 12. The flamearrestor of claim 10, wherein the second means for inducing turbulencecomprises a second plurality of channels that define a second non-linearflow path different from the non-linear flow path.
 13. The flamearrestor of claim 8, wherein each of the channels has a circular,rectangular, or irregular cross-sectional shape.
 14. The flame arrestorof claim 7, wherein the means for inducing turbulence is not a sheet ofexpanded metal disposed in the flame cell.
 15. A method of custommanufacturing a flame arrestor assembly configured to extinguish a flamepropagating therethrough, the method comprising: creating a customizedflame cell using an additive manufacturing technique, the creatingcomprising: forming a body; and forming one or more channels in thebody, the one or more channels defining a flow path configured totransfer heat from a flame front propagating through the flow path tothe body; providing a housing; and securely arranging the flame cellwithin the housing.
 16. The method of claim 15, wherein creating thecustomized flame cell comprises forming a void in the body, the methodfurther comprising arranging a sensor within the void.
 17. The method ofclaim 15, wherein providing the housing comprises creating the housingusing the additive manufacturing technique.
 18. The method of claim 15,further comprising: creating an additional customized flame cell usingthe additive manufacturing technique; and securely arranging theadditional flame cell within the housing.
 19. The method of claim 15,wherein the additive manufacturing technique comprises 3D printing. 20.The method of claim 15, wherein forming the one or more channelscomprises forming one or more curved channels in the body such that theflow path is at least partially non-linear.